Filing tool for hardened-skin care and method of manufacturing the same

ABSTRACT

Disclosed is a filing tool for hardened-skin care, including a plurality of filing parts having double plated nickel and stone powders fixed to such nickel on a metal plate. A method of manufacturing the filing tool is also provided, including setting a patterned photosensitive dry film on the metal plate, exposing the metal plate set with the dry film to light, removing a non-exposed portion of the dry film to form a masking pattern, plating nickel on the metal plate formed with the masking pattern to form a first nickel-plated layer, followed by uniformly applying stone powders on the first nickel-plated layer, further plating nickel on the stone powders to form a second nickel-plated layer, and fixing the stone powders between the first nickel-plated layer and the second nickel-plated layer, followed by removing the masking pattern. Thereby, since the stone powders, serving as a filing material, are securely fixed to nickel, filing efficiencies improve. In addition, the filing tool has higher strength, due to the use of the metal plate.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates, in general, to filing tools forhardened-skin care and manufacturing methods thereof. More specifically,the present invention is directed to a filing tool suitable for use inthe care of hardened-skin, including the nail, the elbow, and the soleof a foot, comprising a plurality of filing parts arranged on a metalplate, and a method of manufacturing the same.

2. Description of the Related Art

In general, filing tools for use on fingernails and hardened-skin havebeen manufactured by various methods. For example, the filing tools areobtained by subjecting a metal surface thereof to a mechanicalprocessing to form fine recesses and protrusions, or by forming fineprotrusions by means of a chemical corrosion, or by attaching a filingmaterial onto a metal plate by use of an adhesive.

However, thusly manufactured filing tools to care for fingernails andhardened-skin are disadvantageous in that parts of filed impuritiesafter such a tool is used for predetermined periods are inserted intothe recesses or filing materials or the attached filing material isseparated from the tool, thus decreasing filing performance.

In addition, there are proposed techniques for forming a plurality ofperforated holes on a filing surface of the filing tool to easily removeimpurities.

However, since sufficient strength is required for the filing tool notto be curved upon filing, the numbers and intervals of the holes arelimitedly formed on the filing surface.

Thus, limitations are imposed on the removal of impurities, wherebyfingernail care or hardened-skin care can be rough.

Korean Utility Model No. 20-0253679 discloses a filing tool,characterized in that removing recesses for removing impurities areformed on a copper foil of a base via a corrosion process, and thecopper foil, with the exception of corroded portions, is attached with afiling material, such as white alumina, having high hardness, mixed in aplating solution via an electroplating process. Thereby, filing partshaving a desired filing performance by high hardness and roughness areprovided, together with removing recesses capable of directly removingfiled impurities.

However, the above technique is disadvantageous in terms of lowproductivity due to complicated processes, including forming the copperfoil on the base, etching the formed copper foil to form the etchedportions to be removing recesses, and fixing white alumina to thenon-etched portions to form filing parts. Further, since the base ismade of a synthetic resin material, it should be thick to maintain adesired strength.

SUMMARY OF THE INVENTION

Therefore, it is an object of the present invention to alleviateproblems encountered in the related art and to provide a filing tool forhardened-skin care, characterized in that a plurality of filing partshave double plated nickel and stone powders securely fixed to suchnickel on a metal plate, thus achieving no separation of the stonepowders from the metal plate, high filing efficiency, higher strengthdue to the use of the metal plate as a base.

Another object of the present invention is to provide a method ofmanufacturing the filing tool.

To achieve the above objects, according to a first embodiment of thepresent invention, there is provided a filing tool for hardened-skincare, comprising a plurality of filing parts formed on a metal plate,wherein the filing parts each include a first nickel-plated layer, asecond nickel-plated layer, and stone powders fixed between the firstand second nickel-plated layers.

According to a second embodiment of the present invention, there isprovided a method of manufacturing a filing tool for hardened-skin carecomprising a plurality of filing parts formed on a metal plate, themethod comprising setting a patterned photosensitive dry film on themetal plate, exposing the metal plate set with the dry film to light,removing a non-exposed portion of the dry film to form a maskingpattern, plating nickel on the metal plate formed with the maskingpattern to form a first nickel-plated layer, followed by uniformlyapplying stone powders on the first nickel-plated layer, further platingnickel on the stone powders to form a second nickel-plated layer, andfixing the stone powders between the first nickel-plated layer and thesecond nickel-plated layer, followed by removing the masking pattern.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other objects, features and other advantages of thepresent invention will be better understood from the following detaileddescription taken in conjunction with the accompanying drawings, inwhich:

FIG. 1 is a perspective view of a filing tool for nail care according toan embodiment of the present invention;

FIG. 2 is a cross-sectional view taken along the line A-A of FIG. 1; and

FIG. 3 is a perspective view of a filing tool for hardened-skin careaccording to another embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Based on the present invention, a filing tool for hardened-skin care isobtained by nickel-plating a metal plate formed with a masking pattern,uniformly dispersing stone powders over the metal plate, and furthernickel-plating the metal plate to fix the stone powders to anickel-plated surface. Hence, the filing tool is advantageous in termsof high filing efficiency due to the stone powders securely fixed tonickel, and higher strength of the metal plate than that of conventionalsynthetic resins. In the present invention, ‘hardened-skin’ is used as aconcept including not only hardened-skin formed around the heel and soleof a foot, or the elbow, but also keratinous skin, such as fingernailsand toenails.

Hereinafter, a detailed description will be given of a filing tool forhardened-skin care and a method of manufacturing the same, withreference to the appended drawings.

FIGS. 1 and 2 show a filing tool for use in hardened-skin caremanufactured by the inventive method. As shown in FIGS. 1 and 2, aplurality of filing parts 12 having predetermined shapes are arranged ona metal plate 11. Further, respective removing recesses 13, serving toremove dead skin resulting from filing hardened-skin, are formed betweenthe adjacent filing parts 12. The filing part 12 includes a firstnickel-plated layer 15 a and a second nickel-plated layer 15 b, andstone powders 14, in which the stone powders 14 are fixed between thefirst and second nickel-plated layers 15 a and 15 b on the metal plate.

Before the setting of a dry film as a first step of the presentinvention, the metal plate 11 as a base is previously subjected to theseries of processes of cutting, acid-cleaning and deburring.Specifically, the metal plate 11 is cut to a predetermined size for easywork, after which the surface of the metal plate 11 is acid-cleaned, andthen impurities are removed (deburred) from the metal plate 11.

In particular, as the metal plate 11, preference is given to usingstainless steel. Also, the variation of the cutting dimension of themetal plate 11 is maintained in the range of ±2 mm. It is important thatstainless steel as a base material is maintained without scratches afterremoving a releasing paper from the stainless steel. In addition, uponthe acid-cleaning, the acid used is preferably hydrochloric acid. Withthe aim of increasing a contact force of a photosensitive dry film, adeburring process is repeatedly performed until the impurities on themetal plate 11 are completely removed. As such, there should be nomoisture on the metal plate 11.

Subsequently, a patterned photosensitive dry film is set on the metalplate 11 (1^(st) step).

As the patterned dry film, use is taken of commercially available onesin the form of films by large companies in Korea and foreign countries.Such a dry film is roll coated and placed on the metal plate 11. In sucha case, it is noted that the dry film is flatly positioned thereon insuch a way that it does not come off the metal plate 11 while unfolded.As well, the dry film should not have impurities. To prevent partialdisposition of the patterns of the dry film, the dry film should beaccurately set on the metal plate 11. Since defective rates increasewhen the patterned film is undesirably placed, the setting state of thefilm should be confirmed.

Then, with the aim of forming a pattern, the metal plate 11 united withthe patterned photosensitive film is exposed to chemical radiation(2^(nd) step).

The patterned dry film includes an exposed portion transmitted withchemical radiation, such as ultraviolet light, and a non-exposed portionthat is not transmitted with ultraviolet light. The exposed portion ofthe dry film is cured by ultraviolet light.

The exposing process is performed under 7-8 kW of ultraviolet light for10-12 sec, depending on the kinds and properties of the photosensitivefilm. Exposure to ultraviolet light, according to normal standardsprovided by manufacturers of photosensitive films, is understood tothose skilled in the art.

Thereafter, the non-exposed portion of the dry film is removed to form amasking pattern on the metal plate 11 (3^(rd) step).

Of the dry film, a portion that is not exposed to ultraviolet light ispresent in the state of not cured, and thus chemically removed by sodiumcarbonate (Na₂CO₃). The exposed portion of the dry film in the state ofcured remains on the metal plate 11 to form a predetermined pattern,which is referred to as a masking pattern.

The masking pattern-formed portion, that is, the exposed portion isremoved following a nickel-plating process as defined later, thereforeresulting in removing recesses 13 of the filing tool. Whereas, theportion without the masking pattern, that is, the non-exposed portion isplated with nickel to form the first and second nickel-plated layers 15a and 15 b, which constitute the filing part 12.

Subsequently, the masking pattern-formed metal plate 11 is plated withnickel and uniformly applied with stone powders 14 (4^(th) step).

The first nickel-plated layer 15 a is preferably 0.20-0.30 μm thick(nickel strike). If the nickel-plated layer 15 a is not in the abovethickness range, a contact force of the nickel strike decreases. Inparticular, the layer 15 a is less than 0.20 μm, the stone powders aredifficult to securely fix thereon.

The stone powders 14 should be uniformly dispersed over the metal plate11 to form a predetermined distribution. Examples of the stone powdersinclude white alumina powders, or ultra small diamond. In cases of thefiling tool for nail care, the stone powders have a particle size of10-15 μm. Meanwhile, in cases of the filing tool for hardened-skin care,the stone powders have an average particle size of 20-25 μm.

As for nickel-plating, the metal plate 11 obtained from the 3^(rd) stepis immersed in a nickel-plating solution and electroplated. As such, thestone powders are uniformly dispersed over the metal plate 11 in thestate of being applied with electricity. Alternatively, the metal plate11 which is connected to a negative electrode may be immersed into thenickel-plating solution containing the stone powders 14, and thenelectroplated. In addition, the application of the nickel and the stonepowders on the metal plate may be carried out by various methods so longas an electroplating process is performed.

The second nickel-plated layer 15 b is further formed on the stonepowders 14 fixed to the first nickel-plated layer 15 a on the metalplate 11 (5^(th) step).

To prevent the separation of the stone powders 14 fixed to the firstnickel-plated layer 15 a, nickel is further electroplated on the stonepowders 14 for 15-20 min, to form the second nickel-plated layer 15 bhaving a thickness of 8-10 μm.

After the stone powders 14 are fixed between the first and secondnickel-plated layers 15 a and 15 b, the masking pattern is removed(6^(th) step).

The removal (separation) of the masking pattern should be performedafter the nickel-plated layers are sufficiently cured in such a way thatthe stone powders are firmly fixed to the nickel-plated layers. Thereby,the filing parts are less damaged. Moreover, the masking pattern formedat the 3^(rd) step, which is a non-nickel-plated portion, is removed at6^(th) step and thus formed to be the removing recesses 13, serving toremove dead skin resulting from filing hardened-skin.

Further, according to another aspect of the present invention, betweenthe 3^(rd) step and the 4^(th) step, the metal plate formed with themasking pattern is cleaned ultrasonically, and then acid-cleaned,followed by activating the surface of the metal plate.

As such, the ultrasonic-cleaning process is performed to remove thenon-exposed portion of the film unnecessarily remaining on the metalplate. Preferably, as a component capable of removing impurities byactivating the surface of the metal plate, commercially availableFerra-BU is used. That is, the metal plate is ultrasonicated for about 1min once to remove the impurities.

The acid-cleaning process is carried out to remove an oxidation film ofthe metal plate. For example, 10% hydrochloric acid is used for 30 sec(once) to eliminate the oxidation film.

The activation of the surface of the metal plate is required to improvea contact force between the metal plate and the nickel. For example, thesurface of stainless steel as the metal plate is activated for about 1min in a range of not bubbling using Makpan82 commercially available asa surfactant (S/S activation).

Furthermore, according to still another aspect of the present invention,the metal plate subjected to the 6^(th) step is acid-cleaned, and thesurface thereof is activated, after which a nickel-plating process isrepeated. Thereby, the surface gloss of the filing tool can beincreased.

Selectively, an additional gloss treatment may be carried out, or aprotective coating film may be formed. In addition, stains generatedduring the above processes may be ultrasonic-cleaned.

Finally, the metal plate is placed into a dryer and dried at 70-80° C.for 10-15 min, cut to a desired shape, confirmed for sizes thereof, andsubjected to common post-treatment, such as trimming, so as not togenerate burrs, thereby completing the filing tool of the presentinvention.

Thusly manufactured filing tool is attached to a plastic body as shownin FIG. 3, and used for care of hardened-skin, say, around the sole andheel of a foot, or the elbow. The filing tool shown in FIG. 3 ismanufactured by attaching the injection-molded body with the metal platehaving the filing parts by use of an adhesive, or by an insert-injectingprocess, which is understood to those skilled in the art.

As for the filing tool for hardened-skin care, the filing parts 12 andthe removing recesses 13 are variously patterned, and filingefficiencies are controlled depending on the sizes of the filing parts12. Thereby, the filing tool is manufactured in the form suitable foruse in hardened-skin care or nail care.

Having generally described this invention, a further understanding canbe obtained by reference to specific preparative examples which areprovided herein for the purposes of illustration only and are notintended to be limiting unless otherwise specified.

EXAMPLE 1

A metal plate of stainless steel was cut, from which a releasing paperfor surface protection was separated. Further, impurities on the surfaceof the metal plate were removed, and the surface thereof was cleanedwith hydrochloric acid (10%) and then dried, after which a patternedphotosensitive dry film was roll coated on a whole surface of the metalplate.

Subsequently, the metal plate set with the patterned photosensitive dryfilm having a pattern of filing parts where circular shapes arerepeatedly arranged was exposed to halogen lamp (8 kW) for 11 sec.

Thereby, the photosensitive dry film was irradiated with ultravioletlight, and a portion transmitted with ultraviolet light (transparentportion in the dry film) was cured. The non-cured portion in the dryfilm was removed with sodium carbonate (Na₂CO₃) and developed, thusforming a desired masking pattern.

The metal plate formed with the masking pattern was immersed into anickel-plating solution and electroplated, to form a first nickel-platedlayer having a thickness of 0.25 μm, on which powders of white aluminahaving an average particle size of 20 μm were dispersed. Thereafter, asecond nickel-plated layer being 9 μm thick was further formed on thewhite alumina powders, after which it was completely cured. Hence, thewhite alumina powders were firmly fixed between the first and secondnickel-plated layers, and then the masking pattern was removed.

Thusly obtained product was ground to increase gloss and cut accordingto product standards, and subjected to common post-treatment, such astrimming, to manufacture a desired filing tool for hardened-skin care.

EXAMPLE 2

A filing tool for hardened-skin care was manufactured in the same manneras in Example 1, with the exception that 10% Ferra-BU was used forultrasonic cleaning for 1 min after the masking pattern had been formed,and 10% hydrochloric acid was used for 30 sec to remove an oxidationfilm of the metal-plate, and Makpan82 was applied for 1 min to increasea contact force of the metal plate, followed by a nickel-platingprocess.

As described above, the present invention provides a filing tool forhardened-skin care and a manufacturing method thereof. The filing toolof the present invention has a plurality of filing parts in which stonepowders are securely fixed between a first nickel-plated layer and asecond nickel-plated layer on a masking pattern-formed metal plate.Thereby, since such stone powders, serving as a filing material, are notseparated from the metal plate, filing efficiencies improve. Inaddition, the filing tool is advantageous in terms of high strength dueto the use of the metal plate as a base.

The present invention has been described in an illustrative manner, andit should be understood that the terminology used is intended to be inthe nature of description rather than of limitations. Many modificationsand variations of the present invention are possible in light of theabove teachings. Therefore, it should be understood that within thescope of the appended claims, the invention may be practiced otherwisethan as specifically described.

1. A filing tool for hardened-skin care, comprising a plurality offiling parts formed on a metal plate, wherein the filing parts eachinclude a first nickel-plated layer, a second nickel-plated layer, andstone powders fixed between the first nickel-plated layer and the secondnickel-plated layer.
 2. A method of manufacturing a filing tool forhardened-skin care comprising a plurality of filing parts formed on ametal plate, the method comprising: first step of setting a patternedphotosensitive dry film on the metal plate; second step of exposing themetal plate set with the dry film to light; third step of removing anon-exposed portion of the dry film to form a masking pattern; fourthstep of plating nickel on the metal plate formed with the maskingpattern to form a first nickel-plated layer, followed by uniformlyapplying stone powders on the first nickel-plated layer; fifth step offurther plating nickel on the stone powders to form a secondnickel-plated layer; and sixth step of fixing the stone powders betweenthe first nickel-plated layer and the second nickel-plated layer,followed by removing the masking pattern.
 3. The method as defined inclaim 2, further comprising ultrasonicating the metal plate formed withthe masking pattern to remove impurities, followed by acid-cleaning themetal plate to remove an oxidation film of the metal plate and thenactivating a surface of the metal plate, between the third step and thefourth step.
 4. The method as defined in claim 2, further comprisingacid-cleaning the metal plate, and then activating a surface of themetal plate, followed by a nickel-plating process, after the sixth step.